JCB India Limited, Jaipur Rajasthan

Interarch in 2014 designed, manufactured and delivered a fabrication shop and assembly shop for JCB India Limitied in Jaipur.The buildings are spread over the area of 30400 Sq. Mt and 22800 Sq. Mt. respectively.

The project is designed according to the latest IS design codes, IS 800: working stress design for both the buildings with consideration given to all the geographical data like wind velocity, seismic zone as per IS standard for every particular site. The lateral forces resulting from the seismic or wind loads are resisted by diagonal bracing and jack portals at intermediate column locations. The design of the building was such that temperature was kept in control for monitoring the thermal expansion and contraction.

The expertise of Interarch design department reduced the engineering time of the fabrication shop and assembly shop which was very complex and new innovation has been done to design the building.Interarch for the first time designed a building bearing heavy load of approximately 225 M hanging from the roof and for the column grid of 40 x 24 M. Higher grade of 450 MPa steel has been used for the built up members.

Interarch had to deploy innovative solutions like highest safety standard which were followed in line with the international standard to achieve zero accident, Logistic and warehousing control at site to meet site standard norms. Daily tool box meeting to review the site status and way forward was done, regular Quality check jointly with client was done & corrective measures to achieve best quality in line with global standard were taken. Highest level of safety standard was showcased by Interarch Project Management team at the site achieving zero accident with over 150 skilled workers working at site.

JCB Testimony

Sunita Hydrocolloids Pvt. Ltd, Jodhpur, Rajasthan

Interarch designed, engineered, and delivered the first Guar Gum building in Pre-Engineered Building technology in India. Interarch was awarded the project for executing new manufacturing facility for Sunita Hydrocolloids Pvt. Ltd. at Jodhpur, Rajasthan using its expertise in complex engineering and innovative design solutions.

Pre-Engineered Building technology was not used for such an application in the recent past, customer preferred only RCC Buildings due to the complexity of the buildings. For the first time Interarch bagged this project of constructing the Guar Gum Building using innovative design technology.

The building is utilized as a process plant for making Guar Gum powder. There are 6 different units or towers in this project. Each tower has 3 levels of floor with deck panel and floor opening for equipment pipelines.

Total height of each tower is 15.3 M. The most important aspect of this project is, all the towers will be covered by a single shed of 33M clear span and a clear height of 23M.

All towers are connected internally by walkway thereby giving it a one point access. Industrial louvers have also been installed for proper ventilation. Each wall has a Liner panel with insulation.

Each floor is designed considering the Static & Dynamic loading and without Cross Bracing and Mezzanine with Bi-directional force transmission with beam.

The project is designed according to the latest IS design codes with consideration given to all the geographical data like wind velocity, seismic zone as per IS standard for particular site.

Key features of the project

Project Name

Sunita Hydrocolloids

Site Location

Jodhpur, Rajasthan

Building Usages

Process plant for the production of Guar Gum Powder.

Design Code

Latest IS design code IS 800:2007

Project Area

2400 Sq. M

Total Tonnage

650 Ton

Special Features

6 Tower Building with G+3 Mezzanine floor (Total height 15.3m of each Tower)

Covering Shed with clear span of 33 M & Clear height of 23M.

Complex Structure made in consideration for both Static & Dynamic load

Interarch expertise in the sector of Rural Retail

The agriculture sector of India has over the years been the single most important component of the economy. In the past two decades a lot of emphasis has been given to the technological developments in the agricultural sector, in order to raise the standard of living and the quality of the produce of farmers. Over the years the sector has evolved using state of art technology and business models to make it commercially successful via public and private enterprises.

Two such examples of innovation in the rural agricultural sector are the much talked about ventures of ITC and DCM Shriram Consolidated Ltd. (DSCL) called Choupal Sagar & Haryaali Kisaan Bazaar respectively. Chaupal Sagar is a rural retail shop & warehouse with a size of 1500 – 2400 Sq m. Harayaali Kisaan Bazaar is a chain of centres across the rural landscape of the country aimed at triggering a qualitative improvement in Indian agriculture. Each centre is spread over 3 to 4 acres of land, in hinterland locations, offers to farmers.

Interarch Building Products Pvt Ltd has been instrumental in the creation of many rural retail projectsacross the country. Their knowledge of warehousing and rural retail and their precision in execution has been brought to the forefront through their exceptional work for Chaupal Sagar and Haryali Kisaan Bazaar.

Interarch played an integral role in bringing up the steel warehouse buildings of Choupal Sagar for ITC in a short span of time with 5 larger than life size buildings across the rural areas of the country; majority being in Uttar Pradesh&Madhya Pradesh. The warehouses were made using Interarch’s much spoken about roofing systems TRACDEK® Hi-Rib Bare galvalume with insulation, with cladding systems of TRACDEK® Hi-Rib SMP.

For Haryaali Kisaan Bazaar Interarch have used TRACDEK® Hi-Rib Bare Galvalume with insulation for the roofing’s while TRACDEK® Hi-Rib SMP Coated Galvalume have been used for cladding. Haryalli Kisaan Bazaar is a rural retail shop & warehouse with a size of 1500 – 2200 sqm. The DSCL venture is currently present in the states of Uttar Pradesh, Punjab, Madhya Pradesh, Haryana, Andhra Pradesh, Rajasthan and Maharashtra.

The success of Choupal Sagar has heralded a new era in the Indian agro-sector. This revolution led to seeding of the idea of raising more such replications in the other untapped areas.

The main reasons for the success of the platform have been the involvement of local farmers and maintenance of the rural IT network by the corporate entity.

Interarch has in its work with both companies, executed various modular systems and has done over 65 buildings in over 65 locations for DSCL Hariyali Kisaan Bazaar and 5 buildings in 5 locations for ITC.

Interarch specialized in setting up 2-3 types of modular buildings that were easily manufactured as per requirement of site within 1 week and shipped to site, assembled and finished in remote locations. Interarch's exceptional abilities in turnkey design, manufacture, supply and execution of such modular systems, enable it to provide fast and effective solutions to remote projects that require standardized, multiple, modular building execution.

Uniqueness of Interarch's Work at DIAL Terminal 3

The Indian PEB industry originally operates on a very stereotypical and
common function, wherein the pre-engineered building supplier comes in at a
stage when most of a project has been conceptualized and architectural details
and elements have been fixed. The PEB supplier then custom designs the building
based on the given requirements of the project, supplies the material and
nominates a third party erector with a team of 30-40 people at max to complete
the execution of the structure. A typical pre-engineered project in India caters
to any simple shed for industrial or warehousing use.

What makes Interarch’s way of working in India different from the rest of its
competition is one of the main reasons that explain the highlights of why the
Interarch work at the IGI-Terminal 3 project stands apart.

Interarch is one of the leading “turnkey” pre-engineered steel construction
solution providers in the country, which by literal definition means that
Interarch is one of the only leading pre-engineered solution providers that has
the in-house capability and knowhow to provide integrated conceptualizing,
design, manufacturing, supply & logistics and, on-site project management and
execution capabilities over its entire pan India operations.

Very few of Interarch’s competitors come close to being able to offer the
turnkey functions and over-all project handling that Interarch offers the
industry. Due to this, Interarch had even before the IGI-T3, executed project of
greater and more complex magnitude on a turnkey basis.

Interarch was chosen amongst many international and Indian-JV bidders from an
international bidding process, to come aboard under lead contractors Larsen &
Tubro and GMR-DIAL, to execute the structural steel works for the Domestic and
International Piers of the Delhi International Airport IGI –Terminal 3 project
as well as the entire roofing system for the entire terminal building.

The IGI-Terminal 3 project would come to be known as one of the largest and
most fast paced projects undertaken by any developer on Indian soil, to be built
in time for the commonwealth games in New Delhi in 2010.

Through its course Interarch would design, manufacture and construct over
7500MT of steel in under 8 months and would design, procure and lay over 1.2
million square meters of roofing material to cover one of the largest buildings
in Asia.

Interarch’s ability to provide complete turnkey solutions in pre-engineered
steel construction and in-house handling of the entire EPC function of this
project led it to become a critical player responsible for the entire Terminal 3
project.

When Interarch was invited to bid for the tender, it was only asked to
consider responsibilities towards the 175,000 sq mt’s of 7-layer
state-of-the-art roofing system that was required for the terminal building.
While studying the project drawings during the bid for the tender, Interarch
design and technical team realized that apart from the roofing for the PIER’s
and the Passenger Terminal Building, the entire superstructure under the roofing
system of the International and Domestic Piers at IGI-T3 were being visualized
by the customer in steel and were ideal for a pre-engineered steel structural
system, rather than the originally planned conventional site fabricated steel
system.

Due to its years of experience in structural steel design, Interarch proposed
to its customer the advantages of considering a pre-engineered structural steel
system for the almost 3km’s of terminal Pier’s.

On advanced design and study under the expert guidance of Interarch design
engineers, Interarch was able to offer a state-of-the-art design solution for
the terminal building piers which would save the project and the customer over
30% in steel tonnage as well as cut the construction time by almost half.

On presentation and acceptance of its abilities customize and value add to
the project in terms of engineering and a complete EPC solution, Interarch
successfully managed to convert the project to a pre-engineered steel system to
aid to the execution speed and the overall longevity of the project design.

Interarch, having an already nationwide presence with manufacturing units all
over the country, went a step ahead in this project and offered one of its
manufacturing units in Greater Noida to be dedicated to cater to the manufacture
of the high-end steel for the fast paced requirements of the IGI –T3 project.
Being located in a 50km radius to the project, Interarch’s Greater Noida
facility took on the challenge to produce some of the largest and most complex,
and utterly mindboggling pre-engineered structural steel systems for the
Terminal 3 project.

Interarch’s project management and contracts division took over a 5 acre
allotted yard space at the project site and built on location its’ offices,
on-site handling, logistics and satellite manufacturing and finishing facility
at the airport site itself.

To save time, Interarch manufactured all its sections in-house in Greater
Noida and shipped them to site over night in lots. Close to over 300,000 parts
and sections were shipped to site along with hardware for assembly during the
course of the project and execution work.

Once the material reached the site, each part and piece of the giant airport
terminal was carefully sorted and put in line for final painting and fire-proof
coating which was undertaken by specialized painting teams and Interarch
sub-contractors at the its site establishment at DIAL T3. Once painting was
completed the parts were sorted with respect to part number and location as per
grid and location tally spanning almost 3km’s of building construction and were
transported upto 2km’s within the site, to the respective work fronts for
assembly by simple bolt-on construction requiring no site welding and cutting
and then lifted piece by piece to the top of the building to form the roof
structure system.

By having everything under its belt from design, manufacture, supply,
logistics and project handling – Interarch took over the responsibilities of the
structural steel work and roofing works from lead contractor L&T, and under its
overall PMC controlled the entire execution and feed to the project site from
its supply chain.

The terminal 3 project was no meager feat and it required multiple handling
of pre-engineered construction activities spread over an area of almost 5 square
km’s and over almost 20 active work fronts on different parts of the building
each with their own dedicated resources for power, construction equipment and
manpower teams, all deployed by Interarch PMC. The Interarch project management
team deployed more than 200 engineers at the site, including heavy construction
equipment, and over 2000 skilled workmen to execute the project work
successfully with safety and quality.

All site coordination was handled from its central control at the DIAL T-3
site office and wireless communication over local radio’s assisted construction
and coordination of the entire project from material handling & feed to front,
to lifting, assembly and final crane lifts to the building location and rooftop.

Interarch shifted an entire team of senior in-house design, manufacture,
project management and construction experts to the DIAL site for a period of
over 10 months to handle the structural steel execution as well as the roofing
of the gigantic terminal building. By coordinating its outputs for an
ever-changing airport site, which required constant pre-planning, planning and
then further re-planning to cater to the dynamic site conditions, along with
constant design and redesign requirements from the customer for interface
details and adaptability and compatibility to various construction aspects,
Interarch was able to give lightening fast response times and streamline its
system dynamically to cater to the project from its design support set up’s
directly at site.

The IGI-Terminal 3 building is the second largest integrated terminal
building of its kind in Asia and its roof covers an area of more than 45 acres.

Once Interarch completed the structural steel design, in-house manufacturing
and execution for the steel package of the project, it commenced operations on
roofing.

Interarch operations were deployed after completion of its pre-engineered
steel structural systems to roof the gigantic building in a world-class
insulated 7 layer roofing system completed in Aluminium.

The entire roof system comprised of 7 independent insulating layers, laid
layer by layer, by hand, over a coverage area of over 45 acres. That led to
almost 7 x 45 = 315 acres of roofing laid in less than 12 months. In engineered
terms, almost 1.3 million square meters of roofing came together using some of
the most tough to handle roofing material in the world.

Interarch project management deployed over 30 roofing teams totaling over
1500 people at their peak, to roof the entire building.

With respect to the roofing aspect of the project, unlike the rest of the
pre-engineered building business in the country, Interarch reached a new level
of command on its position in the industry.

The entire components of the Terminal 3 “pre-engineered 7-Layer roofing
system” was although designed completely in-house by Interarch under the
requirements of the customer and their architects, however, none of the bulk
material in the roofing system were produced by Interarch.

Interarch here achieved a further new dominant role by becoming one of the
largest pre-engineered companies to become buyers of such large volumes of
roofing material under a single contract ever in India. Interarch became the
first pre-engineered steel construction solution company of its kind to source
the best material from all over the world and be in a strong enough financial
position to procure close to Rs 180 crore of material before the project even
commenced.

Interarch designed and built for IGI T3, a roofing system to cater to a STC –
51 criteria for sound transmission, a never before achieved feat in any Indian
airport, as well as insulating properties of U<0.26 W/m2

Each of the 7 layers of the 1.2million square meters of roofing was purchased
by Interarch from the leading material vendors in the world and the completely
imported aluminium skin was imported from Kalzip.

The ability of Interarch to complete the project under the strict safety and
quality guidelines, ensured Interarch would deploy almost 50 dedicated safety
and almost 50 other dedicated quality engineers on the site to ensure the
highest standards of HSE regulations and quality controlled execution.

Interarch faced great unexpected challenges in the project that may have had
consequences to the timelines and safety of the project and worked in all
aspects and under all weather conditions to deliver a completely dry and world
class roofing system.

After the completion of the DIAL IGI Terminal 3 project, Interarch can safely
position itself to be the largest turnkey pre-engineered steel construction
solution provider to have successfully moved from being just a pre-engineered
building company to one of the only EPC Pre-Engineered Steel Construction
Solution Providing giants in India.

Interarch today stands strong and capable of handling any infrastructure and
mission critical project and delivering the entire building in steel.

A New Automotive Empire: Built by Interarch

Interarch’s and Tata Motors association dates back to the 1990’s, when
Interarch started working with the company for roofing projects for their Pune
facilities.Since then, over the last two decades, Interach has been actively
involved in completion of pre-engineered structures for five manufacturing units
for Tata Motors across various locations in the country.

Tata Motors, understanding their limitations to provide high quality personal
vehicles from their Pune truck manufacturing units, took their passenger car
dreams to Uttarakhand in early 2004 with a mega land acquisition and plans to
build the largest greenfield automotive project in the history of the company
and India. Interarch won the bid and turnkey contract to execute the greenfield
pre-engineered building project for the Uttarakhan project.

Interarch collaborated with TATA Motors and with the help of their vetran
in-house planning designed concepts for a completely new manufacturing facility
that would cover almost 250,000 sq meters of production space were made ready.
All buildings had to be designed from scratch keeping in mind the stringent
reqiurements and time limitations of the manufacturer.

Construction work on their first manufacturing facility in was started in
early 2006 in Pantnagar. This facility would cater to the production of their
new innovative ‘Tata Ace’ truck utility vehicle platform. The timeline for the
plant required them to be up and running in under 12 months, for first
production of the new Ace Truck.

Interarch started work with TATA motors at Pantnagar, and set up the entire
facility in under 10 months that was fit out in time and the first test cars
rolled out in 12 months as planned.

Speed of Construction

For any automotive manufacturing facility – right from the point you break
ground for construction, the clock starts ticking for the time one can start
production and hence make the unit economically viable. Interarch’s PEB
solutions are the most suited and proven structures to be able to meet these
tight deadlines without compromising on quality.

Interarch’s manufacturing facility at Pantnagar took the challenge of
manufacturing the complete plant for Tata Motors given all the above
constraints. A total of 10 engineers,15 supervisors along with 800 workers were
on the job over the period to ensure that quality was not compromised and roll
out at the earliest The project which was erected in record time, was handed
over to begin operations in 2 months post completion with a total of 16000 MT of
steel supplied and erected and 354000 Sq. M of roof supplied and installed at
the Pantnagar facility.

Tata Motors – Paint Shops at Pantnagar & Singur

The Paint shop at the facility which also is the largest paint shop in Asia
is 250 m long and has a height of 25 metres.

To save time, Interarch manufactured all the building sections in-house in
the Pantnagar factory and transported them to the construction site overnight in
separate lots. Close to over 300,000 parts and sections were transported to site
along with hardware for assembly during the course of the project execution.

Once the material reached the site, each part and piece for the massive
structure of the manufacturing facility was put in line under a project manager
along with 10 engineers and 15 supervisors. The key highlights for the structure
involved the creation of a mezzanine with two floors along with the conveyor
corridor that connected the assembly shop to the paint shop and the engine shop.
All site coordination was done by Interarch from its Central Control at the
location.

The State-of-the-art facilities include weld shops, paint shops, engine and
gear box shops and assembly lines. TATA Motors has invested close to Rs.1000
crores in the plant. Vendors for the vehicle have made additional investments to
set up their plants in the vendor park adjoining the plant. The operation has
generated about 7500 direct and indirect jobs in the plant, among vendors and
service providers in the area.

The ability of Interarch to complete the project under the strict safety and
quality guidelines, ensured completion of the project within stipulated time
even after facing many challenging situations.

Interarch today stands strong and capable of handling any infrastructure and
mission critical project delivering the highest levels of quality and
innovation.

Spotlight: Tata Nano & ACE Manufacturing Facility

The much spoken about Singur plant of Tata motors from where the Tata Nano
was to be manufactured, was erected in a record time of 6 months and further
finishing took 3 months despite the fact that Interarch faced problems like
loose soil and flooding of the entire paint shop and engine shop.

However, unfortunately, with all the problems that engulfed the Singur plants
operation, Interarch also played a key role in further expansion of the Pant
Nagar plant in Uttarakhand which eventually became the location for rolling out
the Tata Nano and Tata Ace.

Expansion

After the Singur plant was stalled, it became pertinent for Tata to increase
the capacity of the Pantnagar plant in the least possible time, as the roll out
plan for the Nano had to begin.

Interarch has since then built further expansion phases at the Pantnagar
facility to cater to the increasing capacity demands at the production factility.

Group Projects

Interarch has also executed many manufacturing plants for machine tools and
heavy automotive for TATA group comanpanies.

The Tal Manufacturing Solution Ltd plant in Nagpur, a sister company of TATA,
was built by Interarch. Further, Interarch has also executed the manufacturing
plant for Marcopolo buses in Dharwad, a manufacturing facility for earth moving
and mining equipment for Telco Construction Equipment Company,Tata Motors
Facilities in Bangalore and Lucknow, and facilities for the TATA vendor parks -
Ancillary units that feed and support all the manufacturing facilities.

Highest manufacturing Plant delivered in the shortest time for Asian Paints Ltd

The Paint Industry has been growing at a healthy rate over the past few years , Asian Paints is the market leader in decorative paints both distemper as well as emulsion paints. The company has a market share of over 65% of the decorative paints in India. Looking at the current & future demand of the product in market Asian paint decided to construct its 8th greenfield paint manufacturing plant in India with a window of only 8-10 month, the company aims to start production from this facility by mid of this year. The turnkey contract for constructing of this plant near Pune with the initial capacity of 150,000 tonnes was awarded with a value of 40 Cr. to Interarch.

The main challenge in front of Interarch at this time was to finish the project in the stipulated time period along with high safety expectations of the client. Another challenge in front of Interarch was the extreme dimensions of the buildings required by client for manufacturing process and stacking of raw materials, the entire project has 18 buildings in totality had variable heights with buildings towering at those of up to 30 M and had clear spans of upto of 44 M. The total project consumed more than 3000 MT of steel for structural system and around 70,000 Sq. of roofing & sheeting was supplied and installed. The entire pre-engineered steel was manufactured in InterarchPant Nagar plant and to overcome the shortness of time 3 shifts with over 150 workers & supervisor’s was started for nearly 2 months. Separate bays were created in the manufacturing plant to paint the rafters and beams as desired by the client. It took over 2 months to manufacture the steel and roofing system required.

Once at site the erection process of 18 buildings was initially were hard to manage. To satisfy the client safety expectations we had to hire the entire erection team from South East Asia.

Further, to save time no scaffolding were used and only electronic boom lifts were employed with specially trained manpower. For the first time safe roof access of 35 M high was created by Interarch of Pipe Structure and for safety inspection.

Interarch played an integral role in bringing up the steel buildings of Asian Paints in a short span of time with 18 buildings in remote location near Pune. The manufacturing plant were made using Interarch’s much spoken about roofing systems TRACDEK® Standing Seam Roofing system, with cladding systems of TRACDEK® Hi-Rib SMP.

The ability of Interarch to complete the project under the strict safety and quality guidelines ensured Interarch would deploy almost 17-20dedicated safety engineers and almost 15 other dedicated quality engineers on the site to ensure the highest standards of HSE regulations and quality controlled execution

The client has also awarded Interarch Building Products for ensuring safe & healthy work environment at site.

Key Project Highlight

Project Name

Asian Paints Ltd

Building Location

Village Khandala, Pune Satara Road, Maharashtra

Building Usage

Greenfield expansion projects for Asian Paints

Tonnage of building

3,000 MT

Roofing Supplied in MT

70,000 Sq.M

Value of Project

40 Cr.

Area of Project

65000 Sq. M

Important Feature of Project :

Greenfield expansion projects for Asian Paints

Manpower Deployed: 500

Erection of Building : 3 months

Height of the Buildings : 30 M

44 M clear span

Total number of Buildings-18

Completion time of Project 8-10 month

Standing Seam Roof

High safety expectation of the client

Safety Award Won by Asian Paints Ltd

No scaffolding, only electronic boom lifts

International erectors from south east Asia were employed

Safe Roof access of 35 M height was created of pipe structures for
inspection

Expertise of Interarch in the Power Sector

The Indian Pre-Engineered Market is at a very nascent stage currently with very less penetration in few Sectors and one of them is the growing power sector of India which still employees conventional method of construction. This is also the case with Bharat Heavy Electrical Ltd which generally uses conventional method of construction for its manufacturing units across India , the need of power is growing at a very fast pace whereas the supply is still not been able to keep up. BHEL also with very stringent timeline to start a new production line for their Pipe Manufacturing plant which will be utilized in turbines contacted Interarch.

BHEL Trichy, was of high importance to them and would be major manufacturing unit of BHEL family, an ISO9001, 14001 and OHASAS 18001 company also well on its journey towards TQM. After understanding all the requirement and Interarch willingness to execute this project and past history of successfully delivering projects of major power companies like Siemens Ltd,Gujarat Industries Power Company Ltd,BOC India Limited&Crompton Greaves Ltdby Interarch,BHEL awarded the order worth 41 Cr. for design, fabrication, supply and erection of Pre-engineered steel Building for their upcoming Greenfield Project.

The site location of the manufacturing plant was so remote that it was difficult to find un-skilled labour even, with no population in nearby areas Interarch has to arrange for worker from as far as 30 Km. The deadline to complete the project was 8 months for engineering , manufacturing, logistic and complete erection of the buildings. Another major concern was the monsoons and rains. The site was completely flooded with water, due to which the ground got soft and uneven. Work started simultaneously at the site location and Interarch Design Center.

The Project Management team of Interarch shifted their mobile office to site and design engineers started working on the design of the complex building which had a main buildings measuring 230 M X 120 M , with two connecting bay to the main buildings with size 30 M X 180 M.The challenge in front of the design team was to give loading to this building in such a way that the cost quoted for the project does not increase and the connecting building could withstand the weight of 30 MT working craneswhich will be utilized in the manufacturing process. The building has many complex features like multiple EOT all over 20 MT capacities for entire building area running in tandem for multi-station function. & up to 32 m long crane beam unsupported length to meet functional need of manufacturing.

To compensate the air-changes requirements and provide healthy enviornment to the workers inside the manufactuing plant Interarch installed 900 mm throat turbo vents on the roofs for the first time.

The project management team for safety, security, quality and project execution hired around 200 semi-skilled and unskilled labors and stated work with leveling the ground, JCB were employed to finish project in schedule. Once the design was complete the entire manufacturing of 3500 MT of built up took 2 months to manufacture at Interarch pantnagar manufacturing facility as per stringent quality control and inspection provided by the client.

At site highest level of safety and installation procedure was adopted to meet BHEL international standard of working. To complete the erection process in time Interarch employed 2 shifts of workers to work day and night.

The entire erection process of the building has been done through electronically operated boom lifts instead of traditional scaffoldings to meet safety guideline.

Time was very important and with Interarch past history of delivering projects in stipulated time period, we did not take more than a fraction of second to decide to shift the manufacturing of all the roofing and sheeting which will be utilized in the project to the site with all the difficulties in logistic to the site location and security hurdles at site.

The entire manufacturing of 42,000 Sq. M of Interarch TRACDEK® Standing Seam colored roofing system with very lean slope to achieve aesthetic view of the building took place at the site.

Interarch building unique Multistory Warehouse and Cargo facility in New Delhi for Delhi Cargo Service Centre

The versatility of pre-engineered steel buildingsand engineering is rising on the growth curve. Light Pre-engineered buildings, and heavier project work using pre-engineered building solutions have not only proved to be relevant and beneficial to all construction verticals such as Airports, infrastructure, multi-storey buildings, power plants, industrial buildings, manufacturing plants, oil & gas refineries and group housing, but, as little known, they are the most apt and efficient for warehousing, due their highly efficient form of construction.

The range of application of pre-engineered building solutions in airport cargo centers and standalone cargo hubs and distribution centers is huge. Pre-engineered solutions used in cargo and warehousing buildings offer limitless possibilities to the end user. The pre-engineered building design philosophy takes maximum advantage when used in warehousing and cargo, as due their simplistic use for cover and storage, cargo buildings are light and pre-engineered design allows the buildings to be extremely efficient and economical to building, maintain and operate. Interarch has been key in holding flag in cargo and warehousing projects, to name a few, we have constructed large logistic facilities and cargo hubs for companies like Safe Express, GATI Cargo, Hind Terminals, Pipava Port, Dharamtar Port, SurashtraContrainings and Container Coporation of India Ltd.

Going even further our cargo buildings on airside facilities at airports include Air Cargo Warehouse for Indian Airlines, Jet Airways, Spice Jet and the recently inaugurated Delhi Cargo multi-level warehouse complex IGI Airport New Delhi, that was won and completed in 2011.

We in now in the process of building the second phase of this project in 2012

First Green Automotive Manufacturing Plant Built by Interarch in India for Tata Motors Ltd.

Interarch boast in saying that we have designed, produced, erected & delivered almost all but one TATA motors manufacturing plants in India, and that too because of the unforseen difficulties faced in Singur. Even after having a sister company in the Tata Group as our competitor, Interarch has been instrumental in providing and satisfying all the growing needs of not only TATA Motors but other major automotive players like Fiat, GM, Skoda motors, Bajaj across India as well.

For increase in production capacity of its light truck and marcopolo buses, which has strong demand in the Market Tata Motors set-up a new project in Dharwad, Karnataka. The Ace is currently manufactured at the company's Pantnagar plant in Uttarakhand, and the Dharwad plant will be the 2ndfacility for the light-truck, after the production at Pantnagar reached full capacity.

With past history of more than 2 decades and delivery of more than 5 Green field manufacturing projects and over 100 buildings for Tata motors, Interarch was the obvious choice of Tata motors for this project also. Tata motors wanted to construct this plant not only in record time to carter the growing demand of the mini truck , but also wanted the state of the art manufacturing facility to be built with Green building norms. After completion this will be the first Green "Greenfield automotive project" in the history of the company and India.

The green manufacturing facility with numerous buildings like Paint Shop with 4 bays, Engine shop, main plant building, administrative blocks etc. worth 86 Cr was awarded to Interarch. The plants once complete will be spread over an area over 72,000 Sq. M.

Install 3-5 % skylights on the roof of the total roof area of the building which reduces the need of
artificial lights inside the building and saves electricity

The expertise of Interarch design department reduced the engineering time of the manufacturing plant which were very complex, the main building and the paints shop was designed using IS-1984 designed building structure norms with heavy collateral loading to meet all manufacturing and MEP support needs. The paint shop building was even further complex as there were Multilevel mezzanines in the building with heavy collateral load for paint equipment installations and application provided by DURR with lot of auxiliary structure to meet functional requirement.

The Monsoon season & remote location of the site with lean population in the nearby area along with high safety standard required by TATA was a very big challenge.

Interarch had to employee many innovation solutions like highest safety standard followed in line with international standard and TML guideline to achieve zero accident, Logistic and warehousing control at site to meet site standard norms, Daily tool box meeting to review the site status and way forward was done, regular Quality check jointly with client ware done & corrective action to achieve best quality in line with global standard were taken

The entire manufacturing plant consumed more than 5000 MT of steel which was supplied by Interarch manufacturing facilities in less than 4 months.

Highest level of safety standard was showcased by Interarch Project Management team at the site achieving zero accident with over 500 semi-skilled and un-skilled labours employed at the site at the peak time.

To complete the projects in time and to exceed quality norms set by the client Interarch did site roll forming for entire roofing systems, cladding systems, liner etc. This helped in conserving time and we were able to get endless length of the sheeting. The complete manufacturing plant along with the paint shop consumed more than 72,000 Sq. M of roofing and cladding

The ability of Interarch to complete the project under the strict safety and quality guidelineshas made us the market leaders in the Pre-Engineered Buildings Sector.

Key Project Highlightt

Project Name

TATA Motors Ltd

Building Location

Dharwad, Karnataka

Building Usage

Manufacturing Facility

No. of Buildings

11

Tonnage of building

5400 MT

Roofing Supplied in MT

83,000 Sq. M

Value of Project

86 Cr.

Area of Project

72,000 Sq. M

Manpower deployed

500

Important Feature of Project :

Complete factory will designed and manufactured under the norms of Green
Buildings